Heating appliance

ABSTRACT

A heating appliance having a housing which houses a water and air heating system. The water heating system includes a heat source and a first heat exchanger for transferring heat to a working fluid passing through the housing. The air heating system includes a water-to-air heat exchanger in communication with the working fluid and a source of air, for heating air using the working fluid. The housing defines an upper compartment for the heat source and first heat exchanger, and a lower compartment for the water-to-air heat exchanger.

PRIORITY

This application claims priority to Great Britain Patent Application No. GB1307141.0, entitled “HEATING APPLIANCE,” filed on Apr. 19, 2013, also naming Dee et al. as inventors, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present invention generally relates to heating appliances and, more particularly, to a heating appliance which incorporates a water heating device.

BACKGROUND OF THE INVENTION

It is common for a domestic dwelling to include a heating appliance, for providing a source of hot water for bathing and/or use in a central heating system. Such appliances are often referred to generically as ‘boilers’.

There are numerous types of heaters available on the market. Recent years have seen a call for heaters with improved efficiency. A variety of developments have arisen, such as incorporating a power generation mechanism into a heater in order to provide a combined heat and power apparatus. Nevertheless, further advancements are needed.

SUMMARY OF THE INVENTION

Illustrative embodiments of the current invention provide alternative heating appliances. According to one aspect of the invention, there is provided a heating appliance having a housing which houses both a water heating system and an air heating system. The water heating system includes a heat source and a first heat exchanger for transferring heat to a working fluid passing through the housing. The air heating system includes a water-to-air heat exchanger in communication with the working fluid and a source of air, for heating air using the working fluid. The housing defines an upper compartment for the heat source and first heat exchanger, and a lower compartment for the water-to-air heat exchanger.

Other aspects and features of the invention will be readily apparent from the following description of one or more illustrative embodiments, made by way of example, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic view from the front of a heating appliance incorporating a water heating system and an air heating system, according to an illustrative embodiment of the present invention;

FIG. 2 is a schematic view from one side of the heating unit of FIG. 1;

FIG. 3 is a schematic perspective view of the heating unit of FIGS. 1 and 2, with the filter cassette in an open position;

FIG. 4 is similar to FIG. 1 but shows the front cover removed;

FIG. 5 is similar to FIG. 2 but shows the side cover removed;

FIG. 6 is a schematic perspective view showing principal components of the water and air heating systems of the heating unit of FIGS. 1 to 5;

FIG. 7 is an enlarged view from a region of FIG. 6;

FIG. 8 is a schematic view of the heating unit of FIGS. 1 to 7, showing the path of air flow in an air heating mode;

FIG. 9 is a schematic showing the water and air heating circuits of the heating unit; and

FIG. 10 is a schematic showing an illustrative application for the heating unit in a domestic environment.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments and related methods of the present disclosure are described below as they might be employed in a heating appliance incorporating a water and air heating system. In the interest of clarity, not all features of an actual implementation or method are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments and related methodologies of the disclosure will become apparent from consideration of the following description and drawings.

Referring to the illustrative embodiment of FIGS. 1 and 2, a heating appliance is indicated generally at 10. As will be apparent from the following description, the appliance 10 is in the form of a combined air heater and water heater, and so incorporates an air heating system and a water heating system.

The air heating and water heating systems are provided in a common housing 12. As will be described in more detail below, in certain embodiments the primary components of the water heating system are mounted in an upper part of the housing, whereas primary components of the air heating system are provided in a lower part of the housing.

The housing 12 has a top wall 14, a bottom wall 16, opposing side walls 18, a rear wall 20 and a front wall 22. The housing 12 is generally rectangular in cross section. The housing 12 is deeper than it is wide. The housing 12 is configured for floor mounting, e.g. mounting on a plenum on the floor of a building or a similar support structure.

As will be described in more detail below, and as can be seen most clearly from FIG. 3, the top wall 14 includes an air inlet 24 for allowing air to enter the appliance, and a flue turret 26 to allow exhaust gases to exit the appliance. The flue turret 26 is configured for connection to concentric flue ducts. The air inlet 24 is positioned rearward of the flue turret 26, proximal the rear wall 20 of the housing 12. The air inlet 24 is arranged in communication with an air duct of the appliance (described below with reference to FIGS. 4 to 7). In addition, water inflow/outflow pipes 28, 30 extend through the top 14 of the housing 12 (side by side one another, between the air inlet 24 and the flue turret 26), by means of which the appliance 10 can connected as part of a hot water system.

The front wall 22 of the housing 12 is formed from an upper cover 32, a lower cover 34 (located below the upper cover 32) and a central cover 36 (located between the upper cover 32 and the lower cover 34). As will be apparent from the following description, the upper cover 32 is associated with an upper compartment of the housing 12 (for primary components of the water heating system) and the lower cover 34 is associated with a lower compartment of the housing 12 (for primary components of the air heating system).

The central cover 36 forms part of drawer or cassette 38 which is movable along a horizontal axis between a stowed position (shown in FIGS. 1 and 2) and an extended position (e.g. shown in FIG. 3). The cassette forms part of filter system, for filtering air passing from the air inlet 24 to the air heating system, as will be described in more detail below. Accordingly, a replaceable air filter 40 is provided in the cassette 38. A handle 42 is provided for engagement by a user during movement of the cassette 38.

The appliance 10 includes a user interface 44 (i.e. including controls for the appliance 10). In this embodiment, the user interface 44 is mounted behind a movable panel 46. The movable panel 46 is provided in the upper cover 32 of the housing 12. The panel 46 is movable between a closed position (see FIGS. 1 and 2), in which controls on the user interface are hidden from operation, and an open position (e.g. as shown in FIG. 3), in which controls on the user interface 44 can be accessed by a user.

Referring now to the illustrative embodiments of FIGS. 4 and 5, it can be seen that the housing 12 effectively defines two compartments: an upper compartment 48 in which primary components of the water heating system are mounted, and a lower compartment 50 in which primary components of the air heating system are mounted.

Between the upper and lower compartments 48, 50, the appliance 10 defines an intermediate compartment 52 into which the filter cassette 38 can be received. As can be seen most clearly in FIGS. 6 and 7, the intermediate compartment 52 includes running surfaces 54 on which the cassette 38 is slidably movable, i.e. between its stowed and open positions.

An air duct 56 extends from the base of the upper compartment 48 to the air inlet 24. The air duct 56 is used for directing air towards the lower compartment 50 after entering the appliance though the air inlet 24 at the top of the housing 12. Although not visible in the drawings, the lower end of the air duct 56 defines an air outlet, for directing incoming air into the intermediate compartment 52, i.e. so that the air passes through the air filter in the filter cassette 38 when the cassette is in its stowed position. This prevents unwanted particles from entering the lower compartment 50 via the air duct 56.

In general terms, the water heating system includes a heat source mounted in the upper compartment 48 and arranged so that operation of the heat source causes heating of a supply of water. In illustrative embodiments, the heat source takes the form of a gas boiler. In the illustrated embodiment, the heat source takes the form of a gas-fired condensing heat exchanger unit 60, e.g. of known construction. However, other forms of heat source may be incorporated, e.g. other kinds of fuel-fired boilers or heat exchangers, or an engine (e.g. a sterling engine or ic-engine) having a heat exchanger in communication with an exhaust of the engine.

In this illustrative embodiment, the heat exchanger unit 60 is mounted on an outer wall 72 of the air duct 56, by opposing brackets 74. As can be seen, the heat exchanger unit 60 is arranged in front of the air duct 56, with respect to the rear wall 20 of the housing 12. In use, incoming water is directed into the heat exchanger unit 60 via heat conductive pipe work (e.g. copper pipe), where it is heated by heat transfer to the pipe work, and then directed out of the heat exchanger unit 60. This is described in more detail below with reference to FIGS. 7 and 8.

The appliance 10 includes a condensate trap 66. In the illustrated embodiment, the condensate trap 66 is located below the heat exchanger unit 60, more particularly in the lower compartment 50. Condensate is able to flow to the trap 66 under gravity via a condensate conduit 68 arranged between the heat exchanger unit 60 and the condensate trap 66.

In this illustrative embodiment, an external supply of gas is connectable to the appliance 10, e.g. via a cock 69, and the appliance 10 includes a gas valve 70 for controlling the supply of gas to the heat exchanger unit 60. Exhaust gases from operation of the heat exchanger unit 60 are expelled through the roof of the appliance 10 via the flue turret 26 in the top wall 14 of the housing 12.

In general terms, the air heating system consists of a water to air heat exchanger 78 mounted in the lower compartment 50 of the housing 12. In use, heated water from the water heating system is directed down to the lower compartment and through the water to air heat exchanger 78. The air heating system also includes an air fan 76 for collecting air present within the lower compartment (i.e. having passed though the filter cassette 38 from the air duct 56), and an air transition guide 80 for directing air from the air fan 76 to the water to air heat exchanger 78. The fan 76 and air transition guide 80 are mounted in the lower compartment 50.

The water-to-air heat exchanger 78 is mounted on the base wall 16 of the housing 12. In general terms, the water to air heat exchanger 78 consists of a box 82 for receiving air from the transition guide. It also includes plurality of water conduits 84 extending within the box 82. As will be described below, in an air heating mode of operation for the appliance 10, heated water is conveyed through the conduits 84 in order to heat air within the box 82. Although not visible in the drawings, one or more air outlets are provided for directing heated air out of the box 82 and the appliance. The air outlet(s) may, for example, be in the base wall 16 of the housing. One or more air ducts may be connected to the air outlet(s), for conveying the heated air to a demand location remote from the appliance.

FIG. 8 illustrates an illustrative airflow path for the appliance 10 in an air heating mode. Other primary components of the appliance are illustrated schematically in FIG. 9. These include a pump 86, and a diverter valve 88.

An illustrative method of operation for heating water via the appliance 10 will now be described with reference to FIGS. 1 to 9. Water is supplied to the appliance 10 via inlet pipe 28. Pump 86 and diverter valve 88 are operated to cause water to be driven through the heat exchanger unit 60. When the heat exchanger unit 60 is operating, the water is heated as it passes through the heat exchanger unit 60. The user interface can be used to set the desired temperature.

Condensate from operation of the heat exchanger unit 60 is collected in the condensate trap. Any exhaust gases from operation of the heat exchanger unit 60 expelled through the turret 26. The heated water can be delivered to demand location, e.g. external to the appliance 10. However, if air heating is required, at least a proportion of the heated water is diverted to the water-to-air heat exchanger 78. The air circulation fan is operated to draw air into the unit via the inlet 24 and air duct. The air is delivered into the water-to-air heat exchanger 78 and heat is transferred to the air as it passes through the water-to-air heat exchanger 78.

Accordingly, it will be understood that the combined water and air heating appliance 10 is operable to heat water and provide a source of heated air.

The user interface can be used to automate the air-heating and water heating modes of operation, e.g. on a timer. In addition, the unit can be utilized to provide ventilation, by operation of the air fan without the use of heated water in the water-to-air heat exchanger 78. The appliance may be configured to override the warm air heating function if a heated water demand is made to the appliance.

An illustrative use for the appliance 10 is illustrated in FIG. 7, where the appliance 10 forms part of a hot water system 100 in a domestic dwelling. The hot water system 100 includes a water heating circuit 102 and a hot water supply 104. The appliance 10 is used to heat water in the water heating circuit 102. The heated water is then conveyed away from the appliance 10 through a supply conduit 106. The supply conduit 106 directs the heated water to a transfer conduit 108, which extends inside a storage cylinder 110. The transfer conduit 108 is connected between the supply conduit 106 and a return conduit 112, such that the water is directed back to the appliance 10 after passing through the storage cylinder 110, e.g. for reheating and recirculation within the water heating circuit 102.

The storage cylinder 110 receives a supply of water from a cold water storage tank 114. The heated water from the appliance 10 is used to heat the water in the cylinder 110. The heated water in the cylinder can then be used on demand via the hot water supply 104. A feed tank 116 is arranged in communication between the supply conduit 106 and the return conduit 112, in order to complete the water heating circuit 102.

Accordingly, illustrative embodiments of the present invention provide a combined warm air and water heating unit. Separation of the key components of the water heating and warm air heating systems between upper and lower parts of the housing, with incoming air ducted down through the upper part of the housing to the lower part of the housing has been found to optimize packaging of key components of the appliance for use as a floor-mounted heating unit. Mounting the condensing heat exchanger on the air duct has been found to contribute to reduced noise and vibration. Also, arranging the heat source in front of the air duct has allowed for simplified access for maintenance. The provision of a filter system between the two parts of the housing has also provided advantages in terms of packaging, assembly and maintenance. The use of a sliding filter cassette has provided further advantages in this regard.

While certain features and embodiments of the disclosure have been described in detail herein, it will be readily understood that the disclosure encompasses all modifications and enhancements within the scope and spirit of the following claims. Furthermore, no limitations are intended in the details of construction or design herein shown, other than as described in the claims below. Moreover, those skilled in the art will appreciate that description of various components as being oriented vertically or horizontally are not intended as limitations, but are provided for the convenience of describing the disclosure.

It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined herein. 

What is claimed is:
 1. A heating appliance, comprising: a housing for a water heating system and an air heating system, wherein the water heating system is mounted in the housing and comprises: a heat source; and a first heat exchanger for transferring heat to a working fluid passing through the housing, wherein the air heating system is mounted in the housing and comprises a water-to-air heat exchanger in communication with the working fluid and a source of air for heating air using the working fluid, wherein the housing defines an upper compartment for the heat source and first heat exchanger, and wherein the housing defines a lower compartment for the water-to-air heat exchanger.
 2. A heating appliance according to claim 1, wherein: the housing comprises an air inlet; and the air heating system comprises a fan for collecting air entering the housing via the inlet and an air guide for transferring the collected air to the water-to-air heat exchanger.
 3. A heating appliance according to claim 2, wherein the fan and guide are mounted below at least one of the heat source or the first heat exchanger.
 4. A heating appliance according to claim 1, wherein: the air heating system comprises a fan for collecting air and a guide for transferring the collected air to the water-to-air heat exchanger; and the fan and conduit are mounted in the lower compartment.
 5. A heating appliance according to claim 1, wherein: the housing comprises an air inlet to allow air to pass into the housing for supply to the air heating system; and wherein the air inlet is provided in an upper region of the housing.
 6. A heating appliance according to claim 5, wherein: an air duct is arranged in communication with the air inlet; and the air duct is configured to guide incoming air downwards to a location below at least one of the heat source or the first heat exchanger.
 7. A heating appliance according to claim 6, wherein the first heat exchanger is mounted on the air duct.
 8. A heating appliance according to claim 6, wherein the air duct is arranged behind at least one of the heat source or the first heat exchanger with respect to a front face of the housing.
 9. A heating appliance according to claim 7 wherein the air duct is provided in the upper compartment.
 10. A heating appliance according to claim 7, wherein: the air duct is arranged for directing air from the air inlet down through the upper compartment to the lower compartment; air passing into the housing for the air heating system is directed to pass through an air filter before entering the lower compartment; and the air filter is arranged between the upper and lower compartments.
 11. A heating appliance according to claim 10 wherein the housing defines an intermediate chamber between the upper and lower chambers, and the air filter is located in the intermediate chamber.
 12. A heating appliance according to claim 10 wherein the air filter is mounted in a movable cassette or drawer on the housing, movable between a closed position and an open position relative to the housing.
 13. A heating appliance according to claim 1 wherein the heat source and first heat exchanger comprises a gas-fired condensing heat exchanger unit.
 14. A heating appliance according to claim 13, wherein: the gas-fired condensing heat exchanger unit is mounted in an upper compartment of the housing; the air-to-water heat exchanger is mounted in a lower compartment of the housing; and the lower compartment of the housing comprises a condensate trap for receiving condensate from the gas-fired condensing heat exchanger unit in the upper compartment.
 15. A heating appliance according to claim 1, wherein: the heat source is a fuel-fired heat source; the housing comprises a flue terminal for connection to a flue for expelling combustion gases; and the flue terminal is arranged in the roof of the housing.
 16. A heating appliance according to claim 1, further comprising a user interface comprising controls for the appliance, wherein the user interface is mounted in the upper compartment.
 17. A heating appliance according to claim 1, wherein the water-to-air heat exchanger comprises: a box for receiving air to be heated; and a plurality of water conduits for passing the working fluid through the box.
 18. A heating appliance, comprising: a housing for a water heating system and an air heating system, wherein the water heating system is mounted in the housing and comprises: a heat source; and a first heat exchanger for transferring heat to a working fluid passing through the housing, wherein the air heating system is mounted in the housing and comprises a water-to-air heat exchanger in communication with the working fluid and a source of air for heating air using the working fluid, wherein the housing comprises an air inlet to allow air to pass into housing for supply to the air heating system, wherein the air inlet is provided in the roof of the housing, wherein an air duct is arranged in communication with the air inlet, wherein the air duct is configured to guide incoming air downwards to a location below the heat source and/or the first heat exchanger, and wherein the first heat exchanger is mounted on the air duct. 